Embroidery data creation apparatus, embroidery data creation method, embroidery apparatus, liquid discharge apparatus, and non-transitory computer-executable medium

ABSTRACT

An embroidery data creation apparatus includes circuitry. The circuitry creates embroidery data based on an embroidery image, the embroidery image being a source of embroidery to be performed according to the embroidery data using a thread to which multiple colors are applied, the embroidery data being created such that, in an area involving change in a color in the embroidery image, the embroidery is advanced in a first direction being a direction in which a change in the color is smaller than a change in the color in a second direction in which the color changes. The circuitry outputs the created embroidery data.

CROSS-REFERENCE TO RELATED APPLICATION

This patent application is based on and claims priority pursuant to 35 U.S.C. § 119(a) to Japanese Patent Application No. 2022-103470, filed on Jun. 28, 2022, in the Japan Patent Office, the entire disclosure of which is hereby incorporated by reference herein.

BACKGROUND Technical Field

Embodiments of the present disclosure relate to an embroidery data creation apparatus, an embroidery data creation method, an embroidery apparatus, a liquid discharge apparatus, and a non-transitory computer-executable medium.

Related Art

Known embroidery data creation apparatuses create, from an embroidery image that is a source of embroidery, embroidery data associating data of a position to which a needle with which the embroidery is performed is to be moved with a process performed at the corresponding position. Further, known embroidery apparatuses form an embroidery on a recording medium such as a cloth according to embroidery data. Furthermore, known liquid discharge apparatuses discharge liquid onto a recording medium such as a thread used for embroidery.

Some embroidery data creation apparatuses calculate, for each pixel, a line segment (in other words, a direction of the same color or a similar color) indicating a level of continuity of colors in an image such as a photograph, and generate embroidery data such that a pixel of a distinctive color is not hidden by other line segments.

SUMMARY

An embodiment of the present disclosure includes an embroidery data creation apparatus includes circuitry. The circuitry creates embroidery data based on an embroidery image, the embroidery image being a source of embroidery to be performed according to the embroidery data using a thread to which multiple colors are applied, the embroidery data being created such that, in an area involving change in a color in the embroidery image, the embroidery is advanced in a first direction being a direction in which a change in the color is smaller than a change in the color in a second direction in which the color changes. The circuitry outputs the created embroidery data.

An embodiment of the present disclosure includes an embroidery apparatus that includes the embroidery data creation apparatus described above and an embroidery forming section to perform the embroidery according to the embroidery data.

An embodiment of the present disclosure includes a liquid discharge apparatus that includes the embroidery data creation apparatus described above and a liquid discharge section to discharge a liquid as a source of the color to the thread according to the embroidery image and the embroidery data.

An embodiment of the present disclosure includes an embroidery data creation method performed by an embroidery data creation apparatus. The method includes creating embroidery data based on an embroidery image, the embroidery image being a source of embroidery to be performed according to the embroidery data using a thread to which multiple colors are applied, the embroidery data being created such that, in an area involving a change in a color in the embroidery image, the embroidery is advanced in a first direction being a direction in which a change in the color is smaller than a change in the color in a second direction in which the color changes. The method includes outputting the created embroidery data.

An embodiment of the present disclosure includes a non-transitory computer-executable medium storing a program storing instructions which, when executed by a processor of a computer, causes the processor to perform a method. The method includes creating embroidery data based on an embroidery image, the embroidery image being a source of embroidery to be performed according to the embroidery data using a thread to which multiple colors are applied, the embroidery data being created such that, in an area involving a change in a color in the embroidery image, the embroidery is advanced in a first direction being a direction in which a change in the color is smaller than a change in the color in a second direction in which the color changes. The method includes outputting the created embroidery data.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of embodiments of the present disclosure and many of the attendant advantages and features thereof can be readily obtained and understood from the following detailed description with reference to the accompanying drawings, wherein:

FIG. 1 is a diagram illustrating an example of a system configuration of an embroidery system, according to an embodiment of the present disclosure;

FIG. 2 is a side view illustrating an example of a configuration of a dyeing device, according to an embodiment of the present disclosure;

FIG. 3 is a bottom view illustrating an example of a configuration of the dyeing device, according to an embodiment of the present disclosure;

FIG. 4 is a block diagram illustrating an example of a hardware configuration of an embroidery data creation apparatus, according to an embodiment of the present disclosure;

FIG. 5A and FIG. 5B (FIG. 5 ) are block diagrams illustrating an example of a hardware configuration of a dyeing apparatus and an embroidery apparatus, according to an embodiment of the present disclosure;

FIG. 6 is a diagram illustrating an example of a functional configuration of the embroidery system, according to an embodiment of the present disclosure;

FIG. 7 is a schematic diagram illustrating a procedure of creating embroidery data, according to Example 1;

FIG. 8 is a flowchart of an operation of creating embroidery data, according to Example 1;

FIG. 9 is a diagram illustrating a procedure of detecting a color change direction, according to Example 1;

FIG. 10 is a diagram illustrating an embroidery pattern designation user interface, according to Example 1;

FIG. 11 is a schematic diagram illustrating a procedure of creating embroidery data, according to Example 2;

FIG. 12 is a flowchart of an operation of creating embroidery data, according to Example 2;

FIG. 13 is a schematic diagram illustrating a procedure of creating embroidery data, according to Example 3;

FIG. 14 is a flowchart of an operation of creating embroidery data, according to Example 3;

FIG. 15 is a schematic diagram illustrating a procedure of creating embroidery data, according to Comparative Example 1;

FIG. 16 is a diagram illustrating a deviation of color of a thread based on embroidery data, according to Comparative Example 1; and

FIG. 17 is a schematic diagram illustrating a procedure of creating embroidery data, according to Comparative Example 2.

The accompanying drawings are intended to depict embodiments of the present disclosure and should not be interpreted to limit the scope thereof. The accompanying drawings are not to be considered as drawn to scale unless explicitly noted. Also, identical or similar reference numerals designate identical or similar components throughout the several views.

DETAILED DESCRIPTION

In describing embodiments illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the disclosure of this specification is not intended to be limited to the specific terminology so selected and it is to be understood that each specific element includes all technical equivalents that have a similar function, operate in a similar manner, and achieve a similar result.

Referring now to the drawings, embodiments of the present disclosure are described below. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

Embodiments of the present disclosure are described in detail below with reference to the attached drawings. In the drawings, the same components are denoted by the same reference numerals, and redundant descriptions thereof are appropriately omitted below.

System Configuration

A description is given now of a configuration of an embroidery system 3, according to an embodiment. FIG. 1 is a diagram illustrating an example of a configuration of the embroidery system 3. The embroidery system 3 includes an embroidery data creation apparatus 4, the dyeing apparatus 1, and an embroidery apparatus 2. The embroidery data creation apparatus 4, the dyeing apparatus 1, and the embroidery apparatus 2 are communicably connected to each other through a wired network or a wireless network.

Embroidery Data Creation Apparatus

The embroidery data creation apparatus 4 is an information processing apparatus such as a personal computer (PC) installed with a typical operating system (OS). The embroidery data creation apparatus 4 creates embroidery data 41 from an embroidery image 40 that is a source of embroidery.

The embroidery data creation apparatus 4 includes embroidery data conversion software 42 that converts the embroidery image 40 into the embroidery data 41.

The PC is merely one example of the embroidery data creation apparatus 4. The embroidery data creation apparatus 4 is any other suitable apparatus, provided that the apparatus can execute the embroidery data conversion software 42. The embroidery data creation apparatus 4 may be other information processing apparatus such as a tablet terminal, a smartphone, or a personal digital assistant (PDA).

The embroidery data creation apparatus 4 is communicably connected to an external device that is external to the embroidery data creation apparatus 4 through a wired network or a wireless network. The external device is the dyeing apparatus 1 or the embroidery apparatus 2. The dyeing apparatus 1 or the embroidery apparatus 2 is merely one example of the external device.

The external device may be an image forming apparatus such as a scanner, a printer, a copier, a facsimile machine, or a combination thereof, i.e., a multifunction peripheral/product/printer (MFP).

Other examples of the external device include a cloud server, a smartphone, a tablet terminal, an electronic whiteboard, a camera, and a universal serial bus (USB) memory.

The embroidery data conversion software 42 may have a function of creating the embroidery image 40. Alternatively, the embroidery data conversion software 42 may acquire the embroidery image 40 from the external device.

The embroidery image 40 is image data including an original picture of an embroidery design. The original picture of the embroidery design is a design such as an illustration or a photograph including, for example, a plant, a person, an animal, a landscape, a character, a line, a pattern, a letter, a number, and a symbol.

Typical known file formats of the image data include “.jpg” and “.bmp.” The embroidery image 40 may be print data. The print data is data generated by a typical printer driver.

The embroidery image 40 includes color information for each pixel. The color information is, for example, a red, green, and blue (RGB) value representing each color of red, green, and blue with 256 gradations (8 bits: 0 to 255). Alternatively, the color information may be a cyan, magenta, yellow, and key plate (CMYK) value representing each color of cyan, magenta, yellow, and key plate with 101 gradations. The CMYK value is typically a blending amount of colorants of colors included in the print data.

The embroidery data conversion software 42 may convert the color information such as the RGB value or the CMYK value of the embroidery image 40 into color information of a color space as follows:

-   -   (1) Lab value expressed in L*a*b* (L star: hue, a star:         saturation, b star: lightness) color space;     -   (2) HSL value expressed in hue, saturation, and lightness (HSL)         color space.     -   (3) HSV value expressed in hue, saturation, and value (HSV)         color space.

The embroidery image 40 includes an area involving a color change. The area involving a color change is an area in which a certain color gradually or stepwise changes to a different color. An area expressed by, for example, gradation or stripes is an example of the area involving a color change.

The embroidery data conversion software 42 performs image processing on the embroidery image 40 to divide the embroidery image 40 into one or more embroidery areas. Further, the embroidery data conversion software 42 detects, for each of the one or more embroidery areas, area attribute information and automatically determines an embroidery pattern to be applied to each of the one or more embroidery areas. Further, the embroidery data conversion software 42 has a function of receiving an input of, for example, an embroidery area, an embroidery pattern, and area attribute information designated by a user.

For example, in a case that the original picture represents a flower, the embroidery area is, for example, a petal, a stamen, a peduncle, a leaf, and a contour line thereof.

The embroidery pattern is a pattern of embroidery formed by stitches or a combination of various stitches.

The stitch is, for example, a typical running stitch, back stitch, or a satin stitch. The pattern of embroidery is, for example, a plant, a person, an animal, a landscape, a character, a line, a pattern, a letter, a number, or a symbol, each being formed by combining various stitches.

The area attribute information includes, for example, shape information of the embroidery area, color change presence/absence information, a change direction and a change pattern of color in the area involving a color change, and threshold values. The color change presence/absence information indicates whether the embroidery area is the area involving a color change. The shape information of the embroidery area includes information on, for example, a size, a circumferential length, a degree of circularity, a degree of linearity, a length of a major axis, and a length of a minor axis.

The embroidery data conversion software 42 creates the embroidery data 41 that associates a movement position of a needle 21 with which embroidery is to be performed with a process to be performed at the corresponding movement position according to, for example, the embroidery area, the embroidery pattern, or the area attribute information. Typical known file formats of the embroidery data 41 include “.dst” and “.pes.”

Specifically, the process to be performed at the movement position of the needle 21 includes, for example, the processes as follows:

-   -   (1) inserting the needle 21 into a cloth C to catch an upper         thread N and a lower thread B, and then returning the needle 21         to the front side of the cloth C again; thereafter, moving the         needle 21 to a position at which the needle is to be inserted         next;     -   (2) ending or suspending the embroidery (including switching to         another needle 21, or cutting the lower thread B to move the         needle to a different place where the embroidery is not         continuous; and     -   (3) moving the needle 21 to an initialization position         (alignment position).

The movement position of the needle 21 is, for example, a coordinate value in each direction of an X-axis, a Y-axis, and a Z-axis in, for example, an orthogonal coordinate system fixed on a stage 23.

The upper thread N is an example of a thread to which multiple colors are applied. The upper thread N is an example of a recording medium, particularly an example of a linear recording medium. The cloth C is an example of a recording medium on which an embroidery is to be formed.

The recording medium on which the embroidery is to be formed includes paper and the like.

The embroidery data creation apparatus 4 creates the embroidery data 41 (initial embroidery data) for moving the needle 21 when performing embroidery using the upper thread N to which multiple colors are applied. The initial embroidery data is the embroidery data 41 that does not include underlay stitching data for underlay stitching (temporary stitch) that is performed before main embroidery.

The embroidery data creation apparatus 4 transmits the embroidery data 41 (the initial embroidery data) to the embroidery apparatus 2 through a wired or wireless network or via an external device such as a USB memory.

Dyeing Apparatus

The dyeing apparatus 1 is an example of a liquid discharge apparatus that discharges ink onto the upper thread N. The ink is an example of liquid.

The dyeing apparatus 1 includes a dyeing device 103, a nip roller 61, a nip roller 63, and a nip roller 66. The upper thread N is wound in advance around an upper thread spool 101. The dyeing apparatus 1 unwinds the upper thread N from the upper thread spool 101 by the nip roller 61, the nip roller 63, and the nip roller 66 via a roller 102.

The dyeing apparatus 1 discharges ink from the dyeing device 103 to apply the ink to the unwound upper thread N, thereby dying the upper thread N. The dyeing device 103 is an example of a liquid discharge section that discharges liquid. The dyeing device 103 includes a discharge head 30. The discharge head 30 is an example of a head that discharges ink and applies the ink to the upper thread N.

The dyeing device 103 includes a maintenance unit 36 that maintains the discharge head 30 to allow the discharge head 30 to discharge ink. The discharge head 30 collectively refers to multiple discharge heads. The maintenance unit 36 collectively refers to multiple maintenance units.

The nip roller 61, the nip roller 63, and the nip roller 66 are an example of a movement assembly that moves the upper thread N relative to the discharge head 30. Each of the nip roller 61, the nip roller 63, and the nip roller 66 includes a pair of rollers. The nip roller 61, the nip roller 63, and the nip roller 66 convey the upper thread nipped by the pairs of rollers, to move the upper thread relative to the discharge head 30. Alternatively, the movement assembly according to an embodiment may move the discharge head 30 with respect to the upper thread N, to cause the upper thread to move relatively with respect to the discharge head 30.

The dyeing apparatus 1 includes a fixing device 104 to fix ink applied to the upper thread N by the dyeing device 103. The fixing device 104 includes a heater such as an infrared irradiator and a hot air sprayer that heats and dries ink applied to the upper thread N, to fix the ink to the upper thread N.

The dyeing apparatus 1 includes a post-processing device 105 that performs a post-processing of cleaning the upper thread N and applying a lubricant to the surface of the upper thread N.

The dyeing apparatus 1 includes a path length variable conveyance device 106 that conveys the upper thread N while adjusting a conveyance path length of the upper thread N on which the post-processing has been performed by the post-processing device 105. The path length variable conveyance device 106 includes a position sensor 60, the nip roller 61, the nip roller 63, the nip roller 66, and a dancer roller 65.

The dancer roller 65 is provided in the vicinity of an exit of the upper thread N. The dancer roller 65 rotates while supporting the upper thread N, to convey the upper thread N. The dancer roller 65 is elevatable and descendible in a Z direction.

An X direction along the X-axis indicates a direction in which the upper thread N moves relative to the discharge head 30. A Z direction along the Z-axis indicates a vertical direction. A Y direction along the Y-axis indicates a direction substantially orthogonal to the X direction and the Z direction. However, the above-described directions do not limit the orientation of the liquid discharge apparatus in use, and the liquid discharge apparatus may be oriented in any desired direction.

The position sensor 60 includes, for example, a linear encoder and outputs a detection signal of a position of the dancer roller 65. The dyeing apparatus 1 calculates the conveyance path length of the upper thread N according to the detection signal from the position sensor 60.

The dyeing apparatus 1 includes at least the dyeing device 103. In other words, the fixing device 104 and the post-processing device 105 may be omitted.

The dyeing apparatus 1 supplies the upper thread N to the embroidery apparatus 2. Alternatively, the embroidery apparatus 2 may perform embroidery using the upper thread N dyed in advance by the dyeing apparatus 1.

Embroidery Apparatus

The embroidery apparatus 2 includes an embroidery forming section 200. The embroidery forming section 200 includes an embroidery head 20, the needle 21, a lower-thread rotator 22, and the stage 23.

The embroidery head 20 drives the needle 21 through which the upper thread N passes, the lower-thread rotator 22, and the stage 23 so that the upper thread N is entangled with the lower thread B that is supplied from the lower-thread rotator 22 in accordance with the supply of the upper thread N, to perform embroidery on the cloth C.

In the needle 21, the upper thread N is passed through a needle hole at the needle tip. The needle 21 is vertically movable with respect to the cloth C.

The lower-thread rotator 22 includes a lower-thread bobbin 221 around which the lower thread B is wound, and a hook 222. The lower-thread bobbin 221 and the hook 222 rotate in conjunction with the movement of the needle 21. The lower-thread rotator 22 also includes, for example, a cylindrical inner shuttle that accommodates the lower-thread bobbin 221, a bottomed cylindrical outer shuttle, and a cylindrical case integrated with the hook 222.

The lower-thread bobbin 221 illustrated is of a vertical rotation type (a vertical full-rotary shuttle type or a vertical half-rotary shuttle type) in which the rotation direction is the vertical direction. In some embodiments, the lower-thread bobbin 221 may be of a horizontal rotation type (a horizontal shuttle type) in which the rotation direction is the horizontal direction.

The stage 23 is a table that holds the cloth C and includes a through hole through which the needle passes. The stage 23 is movable in the X direction and the Y direction to feed the cloth C.

The “thread” is glass fiber thread, wool thread, cotton thread, synthetic thread, metal thread, mixed thread of wool, cotton, polymer, or metal, yarn, filament, or a linear member (continuous base material) to which liquid can be applied. Examples of the thread include a braid and a flat cord.

Discharge Head

FIG. 2 and FIG. 3 are diagrams illustrating an example of a configuration of the dyeing device 103 according to the present embodiment. FIG. 2 is a side view of the dyeing device 103. FIG. 3 is a bottom view of the dyeing device 103.

As illustrated in FIG. 2 , the dyeing device 103 includes a black discharge head 30K, a cyan discharge head 30C, a magenta discharge head 30M, and a yellow discharge head 30Y.

The dyeing device 103 further includes a black maintenance unit 36K, a cyan maintenance unit 36C, a magenta maintenance unit 36M, and a yellow maintenance unit 36Y. The black discharge head 30K, the cyan discharge head 30C, the magenta discharge head 30M, and the yellow discharge head 30Y respectively form pairs with the black maintenance unit 36K, the cyan maintenance unit 36C, the magenta maintenance unit 36M, and the yellow maintenance unit 36Y. The pairs are provided side by side in the X direction.

As illustrated in FIG. 3 , the discharge head 30 includes multiple nozzles 31 each of which discharges ink. The multiple nozzles 31 are provided side by side in the X direction on a surface 33 of a nozzle plate and form a nozzle row 32. FIG. 3 illustrates an example in which the discharge head 30 includes one nozzle row 32 on the surface 33 of the nozzle plate. Alternatively, the discharge head 30 may include multiple nozzle rows 32 arranged in the Y direction on the surface 33 of the nozzle plate.

The discharge head 30 of FIG. 2 discharges ink from each of the multiple nozzles 31.

The black discharge head 30K discharges black ink. The cyan discharge head 30C discharges cyan ink. The magenta discharge head 30M discharges magenta ink. The yellow discharge head 30Y discharges yellow ink.

The order in which the discharge heads 30 illustrated in FIG. 2 is merely one example. The order may be appropriately changed.

The dyeing device 103 may further include a discharge head that discharges colorless ink for coating the dyed upper thread N most downstream in the X direction.

The maintenance unit 36 faces the discharge head 30 with the upper thread N therebetween, for each color. The maintenance unit 36 performs a maintenance operation such as capping the discharge head 30 when the discharge head 30 is not in use or serving as a dummy discharge receptacle for ink from the discharge head 30. The maintenance unit 36 performs an operation of sucking and circulating ink in the discharge head 30 or performs a wiping operation of the nozzles 31 with the dummy discharge receptacle close to the discharge head 30.

The “capping” refers to an operation of covering the discharge head 30 with a cap that is a lid, to prevent ink in the discharge head 30 from drying. The “dummy discharge” refers to a discharge of ink for discharging thickened ink, and refers to discharge of ink that does not relate to application of ink to the thread. The “dummy discharge receptacle” refers to a member that receives ink discharged by dummy discharge. The “wiping” refers to an operation of wiping the surface 33 of the nozzle plate with, for example, a wiper or a web, to remove dust, thickened ink, and the like adhering to the surface 33 of the nozzle plate.

Hardware Configuration

A description is now given of an electrical hardware configuration of the embroidery system 3.

Embroidery Data Creation Apparatus

Referring to FIG. 4 , a hardware configuration of the embroidery data creation apparatus 4 is described. FIG. 4 is a block diagram illustrating an example of a hardware configuration of the embroidery data creation apparatus 4 according to the present embodiment. The embroidery data creation apparatus 4 is an example of an information processing apparatus.

The embroidery data creation apparatus 4 includes a central processing unit (CPU) 401, a read only memory (ROM) 402, and a random access memory (RAM) 403. The embroidery data creation apparatus 4 includes a hard disk (HD) 404 and a hard disk drive (HDD) controller 405.

The embroidery data creation apparatus 4 includes a display 406, an external device connection interface (I/F) 408, a network I/F 409, and a bus 410. The embroidery data creation apparatus 4 includes a keyboard 411, a pointing device 412, an optical drive 414, and a medium I/F 416. The display 406, the keyboard 411, and the pointing device 412 are examples of a user interface.

The CPU 401 controls overall operation of the embroidery data creation apparatus 4.

The ROM 402 stores programs such as an initial program loader (IPL) to boot the CPU 401.

The RAM 403 is used as a work area for the CPU 401. The RAM 403 is an example of a volatile memory.

The HD 404 stores various data such as a program. The HD 404 is an example of a nonvolatile storage.

The HDD controller 405 controls reading and writing of various data from and to the HD 404 under control of the CPU 401.

The display 406 displays various information such as a cursor, menu, window, characters, or image. The display 406 is, for example, a touch panel display that receives a hand drafted input with a stylus or a fingertip. The display 406 is preferably implemented by electronic paper with high recognizability.

The external device connection I/F 408 is an interface that connects the embroidery data creation apparatus 4 to various external devices. Examples of the external device include a USB memory, a scanner, a printer, a copier, and an MFP.

The network I/F 409 is an interface via which the embroidery data creation apparatus 4 communicates data with various external devices through a network I. The network I/F 409 communicably connects the embroidery data creation apparatus 4 to the dyeing apparatus 1, the embroidery apparatus 2, or the like through the network I. The network I/F 409 communicably connects the embroidery data creation apparatus 4 to an external device such as a cloud server or a personal computer (PC) external to the embroidery system 3 through the network I, to allow the embroidery data creation apparatus 4 to download various programs from the external device and install the downloaded programs.

The bus 410 electrically connects various hardware such as the CPU 401. The bus 410 includes, for example, an address bus and a data bus.

The keyboard 411 is an example of an input device (input means) of the embroidery data creation apparatus 4 provided with a plurality of keys that allows a user to input characters, numerals, and various instructions.

The pointing device 412 is an example of an input device (input means) of the embroidery data creation apparatus 4 that allows a user to select or execute a specific instruction, select a target for processing, or move a cursor being displayed.

The optical drive 414 controls reading or writing of various data from or to a storage medium 413 that is detachable. The storage medium 413 includes, for example, a compact disc-recordable (CD-R), a compact disc rewritable (CD-RW), a digital versatile disc recordable (DVD-R), or a digital versatile disc rewritable (DVD-RW). The medium I/F 416 controls reading and writing (storing) of various data from and to a storage medium 415 such as a flash memory. The storage medium 415 is an example of a nonvolatile memory.

Dyeing Apparatus

FIG. 5A and FIG. 5B (FIG. 5 ) are block diagrams illustrating an example of a hardware configuration of the dyeing apparatus 1 and the embroidery apparatus 2 according to the present embodiment. The dyeing apparatus 1 includes a first communication interface 109, a first computation unit 108, and a head driver 39.

The first communication interface 109 is an interface that allows the dyeing apparatus 1 to communicate data with an external device that is external to the dyeing apparatus 1 through a wired network or a wireless network. Examples of the first communication interface 109 include a wireless module and a network I/F. Alternatively, the first communication interface 109 may be an external device connection I/F that connects the dyeing apparatus 1 to an external device such as a USB memory or an image forming apparatus.

The first computation unit 108 is a main controller of the dyeing apparatus 1. The first computation unit 108 is implemented by a computer including, for example, a CPU, a RAM, and a ROM.

The first computation unit 108 acquires the embroidery image 40 and the embroidery data 41 (initial embroidery data) from the external device via the first communication interface 109. The first computation unit 108 creates dyeing data according to the embroidery image 40 and the embroidery data 41.

The dyeing data includes a blending amount of colors of CMYK used for dyeing the upper thread N and a dyeing continuous length of the upper thread N. The dyeing continuous length indicates a length of the upper thread N that is dyed in the same color. The dyeing data further includes a redundant dyeing length at a color switch point of the upper thread N and turn-back marker information set at the midpoint of the redundant dyeing length.

A redundant dyeing area of the upper thread N is used as an area for an underlay stitching (temporary stitch) that is performed before main embroidery. Alternatively or additionally, the redundant dyeing area is used as an area for adjusting a consumption amount of the upper thread N. Alternatively or additionally, the redundant dyeing area is used as an area for adjusting color at the color switch point of the upper thread N.

The first computation unit 108 sends a dyeing command obtained by processing the dyeing data to the head driver 39.

On the basis of the dyeing command, the head driver 39 drives the discharge head 30 so as to dye the upper thread N according to, for example, the blending amount of the colors and the dyeing continuous length, to cause ink to be discharged from the nozzle 31.

The dyeing apparatus 1 further includes a rotary encoder 613, an entry motor 68, an entry drive roller 611, a central motor 69, and a central drive roller 631.

The dyeing apparatus 1 may internally include the functions of the embroidery data creation apparatus 4.

Embroidery Apparatus

The embroidery apparatus 2 includes a second communication interface 201, a second computation unit 25, a motor driver 26, a drive motor 27, a needle up-down driving unit 281, a lower-thread rotation driving unit 282, an X-axis driving unit 283, a Y-axis driving unit 284, and a stitch sensor 29.

The second communication interface 201 is an interface that allows the embroidery apparatus 2 to communicate data with an external device that is external to the embroidery apparatus 2 through a wired network or a wireless network. Examples of the second communication interface 201 include a wireless module and a network I/F.

Alternatively, the second communication interface 201 may be an external device connection I/F that connects the embroidery apparatus 2 to an external device such as a USB memory or an image forming apparatus.

The second computation unit 25 is a main controller of the embroidery apparatus 2. The second computation unit 25 is implemented by a computer including, for example, a CPU, a RAM, and a ROM.

The second computation unit 25 acquires the embroidery data 41 (initial embroidery data) from the external device via the second communication interface 201. The second computation unit 25 acquires dyeing data from the external device via the second communication interface 201.

The second computation unit 25 creates underlay stitching data according to the dyeing data, and creates the embroidery data 41 obtained by adding the underlay stitching data to the initial embroidery data.

The underlay stitching data is data for underlay stitching that is performed using the redundant dyeing area of the upper thread N. Like the initial embroidery data, the underlay stitching data is data associating the movement position of the needle with which embroidery is to be performed with a process to be performed at the corresponding movement position.

The second computation unit 25 sends an operation command obtained by processing the embroidery data 41 to the motor driver 26.

The motor driver 26 drives the drive motor 27 according to the operation command. The drive motor 27 operates the needle 21, the lower-thread rotator 22, and the stage 23.

The needle up-down driving unit 281 is referred to as a balance. The needle up-down driving unit 281 converts a rotational movement of an upper shaft coupled to the drive motor 27 into a vertical movement, to cause the needle 21 through which the upper thread N is passed move vertically.

The lower-thread rotation driving unit 282 rotates the lower-thread rotator 22 in conjunction with the vertical movement of the needle 21 by the rotational movement of a lower shaft coupled to the upper shaft via, for example, a belt, a cam, and a crank. The upper shaft is coupled to the drive motor 27.

The X-axis driving unit 283 and the Y-axis driving unit 284 move the stage 23. The X-axis driving unit 283 and the Y-axis driving unit 284 drive the movement of the stage 23, on which the cloth C is placed, in the X direction and the Y direction in conjunction with the vertical movement of the needle 21 and the rotation of the lower-thread rotator 22 by the rotational movement of the lower shaft. The cloth C may be fed by moving the entire stage 23 or by moving a feed dog provided on a hole formed in the stage 23.

The needle up-down driving unit 281, the lower-thread rotation driving unit 282, the X-axis driving unit 283, and the Y-axis driving unit 284 configure a stage driving unit 28 that is driven in conjunction with one drive motor 27. The vertical movement of the needle 21, the rotational movement of the lower-thread rotator 22, and the X-and-Y movement of the cloth C on the stage 23 are generated by the rotation of the drive motor 27. For example, one vertical movement of the needle 21 is performed in conjunction with one or an integral number of rotational movements of the lower-thread rotator 22.

The stitch sensor 29 is a sensor that detects vertical movement of the needle 21. The stitch sensor 29 is provided, for example, on a needle bar that holds the needle 21. The stitch sensor 29 detects the number of stitches corresponding to how many times the needle 21 has moved up and down, in other words, how many stitches have been advanced by the needle 21.

The second computation unit 25 calculates a consumption amount of the upper thread N on the basis of the embroidery data 41 and the progress status (stitch data) indicating how many stitches have been advanced detected by the stitch sensor 29. The second computation unit 25 notifies the first computation unit 108 of the dyeing apparatus 1 of the thread consumption amount.

The embroidery apparatus 2 may internally include the functions of the embroidery data creation apparatus 4.

Functional Configuration

A description is now given of a functional configuration of the embroidery system 3. FIG. 6 is a block diagram illustrating an example of a functional configuration of the embroidery system 3 according to the present embodiment.

Embroidery Data Creation Apparatus

The embroidery data creation apparatus 4 includes the embroidery data conversion software 42. The embroidery data conversion software 42 includes a user interface unit 420 and an image processing unit 421.

Functions of the embroidery data conversion software 42 are implemented by processing that one or more programs installed in the embroidery data creation apparatus 4 cause a processor such as the CPU 401 to execute.

Some of the functions of the embroidery data conversion software 42 may be allocated to an external device such as the dyeing apparatus 1, the embroidery apparatus 2, a cloud server, or an image forming apparatus.

The embroidery data creation apparatus 4 includes an embroidery pattern storage unit 430, an embroidery data storage unit 431, and a third communication control unit 432.

The embroidery pattern storage unit 430 and the embroidery data storage unit 431 are implemented by a storage such as a HD 404 or a nonvolatile memory such as the storage medium 415.

A function of the third communication control unit 432 is implemented by processing that one or more programs installed in the embroidery data creation apparatus 4 cause a processor such as the CPU 401 to execute.

The functions of the embroidery pattern storage unit 430 and the embroidery data storage unit 431 may be allocated to an external device such as the dyeing apparatus 1, the embroidery apparatus 2, a cloud server, or an image forming apparatus.

The user interface unit 420 causes a user interface such as the display 406 to display various information and receives an input of various information designated by a user via a user interface such as the pointing device 412.

The user interface unit 420 includes at least one of an embroidery image acquisition unit 422, an embroidery area designation unit 424, an embroidery pattern designation unit 428, and an area attribute designation unit 429.

The image processing unit 421 performs image processing on the embroidery image 40 to process various information to be used to create the embroidery data 41.

The image processing unit 421 includes at least one of an embroidery area determination unit 423, an area attribute detection unit 425, an embroidery pattern determination unit 426, and an embroidery data creation unit 427.

The embroidery pattern storage unit 430 stores an embroidery pattern such as a stitch or a pattern of embroidery in association with area attribute information of an embroidery area. The embroidery pattern storage unit 430 stores, for example, an embroidery pattern corresponding to a change direction of color and a change pattern of color in an area involving the color change.

The embroidery data storage unit 431 stores the embroidery image 40 and the embroidery data 41 corresponding to the embroidery image 40.

The third communication control unit 432 controls wired or wireless data communication with an external device such as the dyeing apparatus 1, the embroidery apparatus 2, the cloud server, the image forming apparatus, and the USB memory.

The embroidery image acquisition unit 422 reads the embroidery image 40 from the embroidery data storage unit 431 and causes a user interface such as the display 406 to display the embroidery image 40. The embroidery image acquisition unit 422 may acquire the embroidery image 40 from the external device via the third communication control unit 432.

The embroidery image acquisition unit 422 acquires the embroidery image 40 as print data from, for example, a printer driver or an image forming apparatus.

The embroidery area determination unit 423 performs image processing on the embroidery image 40, to automatically determines one or more embroidery areas from the embroidery image 40.

The embroidery area designation unit 424 causes a user interface such as the display 406 to display the embroidery image 40 and receives an input of an embroidery area designated by a user via a user interface such as the pointing device 412.

The area attribute detection unit 425 automatically detects area attribute information of the embroidery area. The area attribute detection unit 425 automatically detects, for example, color change presence/absence information and a change direction of color and a change pattern of color in the area involving a color change. The color change presence/absence information indicates whether the embroidery area is the area involving a color change.

The embroidery pattern determination unit 426 automatically determines an embroidery pattern according to the area attribute information of the embroidery area. The embroidery pattern determination unit 426 automatically determines, for example, an embroidery pattern in which stitches of a thread of the embroidery pattern run in a direction in which a color change is smaller than a color change in the color change direction in the area involving the color change. Alternatively, the embroidery pattern determination unit 426 reads out from the embroidery pattern storage unit 430 an embroidery pattern corresponding to the color change direction and color change pattern designated by the user, for example, and automatically determines the read embroidery pattern as an embroidery pattern.

The embroidery pattern designation unit 428 causes the display 406 to display candidates of an embroidery pattern and receives an input of an embroidery pattern designated by the user.

The area attribute designation unit 429 allows the user to designate area attribute information of an embroidery area on a user interface such as the display 406, and receives an input of the area attribute information designated by the user via a user interface such as the pointing device 412. The area attribute information of the embroidery area is, for example, a change direction of color and a change pattern of color in an area involving a color change.

The embroidery data creation unit 427 creates the embroidery data 41 that associates a movement position of a needle with which embroidery is to be performed with a process to be performed at the corresponding movement position according to at least one of the embroidery pattern and the area attribute information.

The embroidery data creation unit 427 outputs the created embroidery data 41. For example, the embroidery data creation unit 427 stores, the embroidery data storage unit 431, the embroidery data 41 in association with the embroidery image 40. Alternatively, the embroidery data creation unit 427 outputs the created embroidery data 41 to an external device such as the dyeing apparatus 1 or the embroidery apparatus 2 via the third communication control unit 432.

Dyeing Apparatus

The dyeing apparatus 1 includes a first communication control unit 120 and a dyeing data processing unit 121.

Functions of the first communication control unit 120 and the dyeing data processing unit 121 are implemented by processing that one or more programs installed in the dyeing apparatus 1 cause a processor in the first computation unit 108 to execute.

The function of the dyeing data processing unit 121 may be allocated to an external device such as the embroidery data creation apparatus 4, the embroidery apparatus 2, a cloud server, or an image forming apparatus.

The first communication control unit 120 controls wired or wireless data communication with an external device such as the embroidery data creation apparatus 4, the embroidery apparatus 2, the cloud server, the image forming apparatus, and the USB memory via the first communication interface 109.

The first communication control unit 120 receives the embroidery image 40 and the embroidery data 41 (initial embroidery data) corresponding to the embroidery image 40 from the external device.

The dyeing data processing unit 121 creates dyeing data according to the embroidery image 40 and the embroidery data 41 corresponding to the embroidery image 40. The dyeing data processing unit 121 sends a dyeing command obtained by processing the dyeing data to the head driver 39.

The first communication control unit 120 transmits the dyeing data to the embroidery apparatus 2.

Embroidery Apparatus

The embroidery apparatus 2 includes a second communication control unit 240 and an embroidery data processing unit 241.

Functions of the second communication control unit 240 and the embroidery data processing unit 241 are implemented by processing that one or more programs installed in the embroidery apparatus 2 cause a processor in the second computation unit 25 to execute.

The function of the embroidery data processing unit 241 may be allocated to an external device such as the embroidery data creation apparatus 4, the dyeing apparatus 1, a cloud server, or an image forming apparatus.

The second communication control unit 240 controls wired or wireless data communication with an external device such as the embroidery data creation apparatus 4, the dyeing apparatus 1, the cloud server, the image forming apparatus, and the USB memory.

The second communication control unit 240 receives the embroidery data 41 (initial embroidery data) and the dyeing data corresponding to the embroidery data 41 from the external device via the second communication interface 201.

The embroidery data processing unit 241 generates underlay stitching data according to the embroidery data 41 (initial embroidery data) and the dyeing data corresponding to the embroidery data 41.

The embroidery data processing unit 241 creates the embroidery data 41 obtained by adding the underlay stitching data to the initial embroidery data. The embroidery data processing unit 241 sends an operation command obtained by processing the embroidery data 41 to the motor driver 26.

Example 1

Referring to FIG. 7 to FIG. 10 , a procedure of creating embroidery data according to Example 1 is described. FIG. 7 is a schematic diagram illustrating a procedure of creating embroidery data according to Example 1.

The embroidery image 40 is an original picture of a flower having areas in which color changes gradually or stepwise.

The embroidery image 40 includes a petal 441, a stamen 442, a peduncle 443, and a leaf 444.

The color of the petal 441 gradually or stepwise changes from white to red from the stamen 442 side toward the outward of the petal 441. A contour line of the petal 441 is drawn in black.

The image processing unit 421 automatically determines, from the embroidery image 40 of the flower, embroidery areas such as the petal 441, the stamen 442, the peduncle 443, the leaf 444, and the contour lines thereof.

The user interface unit 420 displays the determined embroidery areas on the display 406, and receives an input of the embroidery area of the petal 441 designated by a user.

The image processing unit 421 detects that the embroidery area of the petal 441 designated by the user is an area 450 involving a color change.

In a case that the embroidery area of the petal 441 is the area 450 involving a color change, the image processing unit 421 detects a direction CD in which the color changes in the area 450 involving a color change.

The user interface unit 420 causes the display 406 to display a candidate of an embroidery pattern 452 (stitches or a pattern of embroidery) in which a needle moves in a direction SD in which a change in color is smaller than the direction CD in which the color changes. The direction SD in which a change in color is smaller is an example of a first direction. The direction CD in which the color changes is an example of a second direction.

The embroidery pattern 452 is, for example, a running stitch in which a thread runs in the direction SD in which a change in color is small. The embroidery pattern 452 may be, in alternative to a stitch, a pattern of embroidery such as a flower in which the needle moves in the direction SD in which a change in color is small.

The user interface unit 420 allows a user to designate a desired embroidery pattern 452 from among candidates for the embroidery pattern 452.

According to the embroidery pattern 452 designated by the user, the image processing unit 421 creates the embroidery data 41 so that the needle moves in the direction SD in which a change in color is smaller than a change in color in the direction CD in which a color changes.

Flowchart of Creating Embroidery Data

Referring to FIG. 7 and FIG. 8 , a specific procedure of generating the embroidery data 41 according to the present example is described.

FIG. 8 is a flowchart of an operation of creating embroidery data according to the present example.

The embroidery area determination unit 423 performs image processing such as contour extraction, expansion, contraction, and binarization on the embroidery image 40 including the original picture of a flower, to extract contour line areas such as the petal 441, the stamen 442, the peduncle 443 and the leaf 444.

According to the color information of each pixel, the embroidery area determination unit 423 extracts color connection areas such as the petal 441, the stamen 442, the peduncle 443, and the leaf 444, which include connected pixels of the same color or the similar color.

The embroidery area determination unit 423 automatically determines the contour line areas and the color connection areas as the embroidery areas (step S100).

The embroidery area designation unit 424 receives an input of an embroidery area of, for example, the petal 441 that is designated by the user from among the determined embroidery areas (step S101).

The area attribute detection unit 425 detects area attribute information such as color variation in the embroidery area of the petal 441 designated by the user (step S102). The color variation is, for example, a color dispersion value in the embroidery area of the petal 441. The color variation may be a standard deviation value.

When the color variation in the embroidery area of the petal 441 is equal to or greater than a threshold value (YES in step S103), the area attribute detection unit 425 determines the embroidery area of the petal 441 designated by the user as the area 450 involving a color change (color change area) (step S104).

When the color variation in the embroidery area of the petal 441 is less than the threshold value (NO in step S103), the area attribute detection unit 425 determines the embroidery area of the petal 441 designated by the user as an area not involving a color change (color constant area) (step S105).

The area attribute detection unit 425 detects the direction CD in which a color changes in the area 450 involving a color change (step S106).

The embroidery pattern determination unit 426 automatically determines candidates for the embroidery pattern 452 in which the needle moves in the direction SD in which a change in color is smaller than a change in color in the direction in which the color changes (step S107).

The embroidery pattern 452 in which the needle moves in the direction SD in which a change in color is small is a stich in which a thread seam that appears on the front side of the embroidery pattern 452 runs in the direction SD in which a change in color is small. Alternatively, the embroidery pattern 452 in which the needle moves in the direction SD in which a change in color is small is a pattern of embroidery in which the needle moves in the direction SD in which a change in color is small.

By contrast, when the embroidery area designated by the user is an area 451 not involving a color change (color constant area) (step S105), the embroidery pattern determination unit 426 determines a candidate for the embroidery pattern 452 according to the area attribute information such as a shape (step S107). The area 451 not involving a color change is, for example, a contour line area of the petal 441.

The embroidery pattern designation unit 428 causes the display 406 to display candidates of the embroidery pattern 452 and receive an input of an embroidery pattern designated by the user (step S108).

According to the embroidery pattern 452 designated by the user, the embroidery data creation unit 427 creates the embroidery data 41 according to which the needle 21 moves in the direction SD in which a change in color is smaller than a change in color in the direction CD in which a color changes and outputs the created embroidery data 41 (step S109).

That is, the embroidery data creation unit 427 creates the embroidery data 41 so that embroidery is performed preferentially in the direction SD in which a change in color is small. In other words, the embroidery data creation unit 427 creates the embroidery data 41 such that embroidery is continuously performed in a portion of the same color or a similar color in the area 450 involving a color change. A range of the same color or the similar colors is a range of a color difference AE determined in advance.

Procedure of Detecting Direction of Color Change

Referring to FIG. 9 , a specific procedure of detecting the direction CD in which a color changes is described. FIG. 9 is a diagram for describing a procedure of detecting the direction CD in which a color changes according to the present example. FIG. 9 illustrates a group of pixels corresponding to the petal 441 in the embroidery image 40.

The area attribute detection unit 425 calculates color differences AE between color information of a target pixel 460 (indicated by diagonal hatching) and color information of eight adjacent pixels 461 that are adjacent to the target pixel 460 in the area 450 involving a color change.

The color difference AE is a Euclidean distance between two points in a color space such as RGB, CMYK, Lab, HSL, or HSV. AE*ab is an example of a color difference.

The area attribute detection unit 425 calculates, for each pixel, a direction from the target pixel 460 toward the particular adjacent pixel 461 (indicated by dot hatching) having the largest color difference AE among the eight adjacent pixels 461.

The area attribute detection unit 425 detects, for each pixel, a direction from the target pixel 460 toward the adjacent pixel 461 having the largest color difference AE and a color change vector CV having the color difference AE. The direction of the color change vector CV is, for example, an angle around the Z-axis in the image coordinate system. The magnitude of the color change vector CV is the color difference AE.

The area attribute detection unit 425 detects an average value or a median value of the color change vectors CV of the pixels in the area 450 involving a color change as the direction CD in which the color of the area 450 involving a color change changes.

The area attribute detection unit 425 detects, for example, a direction orthogonal to the color change vector CV as the color constant vector SV indicating a direction in which a color change is small. The direction of the color constant vector SV is, for example, an angle around the Z-axis in the image coordinate system. The magnitude of the color constant vector SV is the color difference AE.

The area attribute detection unit 425 detects an average value or a median value of the color constant vectors SV of the pixels as the direction SD in which the color change is small in the area 450 involving a color change.

User Interface

Referring to FIG. 10 , an embroidery pattern designation user interface 500 according to the present example is described. FIG. 10 is a diagram illustrating the embroidery pattern designation user interface 500 according to the present example.

FIG. 10 illustrates the embroidery pattern designation user interface 500 in the embroidery data conversion software 42.

The embroidery pattern designation unit 428 causes the display 406 to display the embroidery pattern designation user interface 500.

The embroidery pattern designation user interface 500 includes an embroidery image view 501 and an embroidery pattern candidate view 502.

The embroidery image view 501 displays the embroidery image 40. The embroidery image view 501 displays the area 450 involving a color change designated by the user and the embroidery pattern 452 applied to the area 450 involving a color change.

The embroidery pattern candidate view 502 displays a candidate 504 for the embroidery pattern 452 that can be applied to the area 450 involving a color change and a selection portion 505 that receives a selection of the candidate 504 for the embroidery pattern 452.

The embroidery image view 501 displays the embroidery pattern 452 such as a running stitch in which a thread seam runs in the direction SD in which a change in color is small is displayed in the embroidery image 40 applied to the area 450 involving a color change.

The embroidery pattern candidate view 502 displays the area 450 involving a color change designated by the user to which a candidate 504 of the embroidery pattern 452 such as a satin stitch or a chain stitch in which a thread seam runs in the direction SD in which a color change is small is applied.

When the candidate 504 of the satin stitch is selected with the selection portion 505, the embroidery pattern designation unit 428 causes the display 406 to display the embroidery image view 501 in which the embroidery pattern 452 is converted from the running stitch to the satin stitch.

When the embroidery pattern 452 is designated with a designation part 506 for all the embroidery areas, the embroidery pattern designation unit 428 receives an input of the embroidery pattern 452 designated by the user in association with each embroidery area.

According to Example 1, the embroidery data 41 is created according to an embroidery pattern designated by a user from among candidates for the embroidery pattern 452 in which the needle moves in the direction SD in which a change in color is small.

Thus, even when an amount of consumption of the upper thread N fluctuates while actually performing embroidery and therefore deviation of color of the upper thread N occurs, the deviation of color is less recognizable. In other words, when embroidery is performed using the upper thread N to which multiple colors are applied, a change in color in the embroidery image 40 is reproducible. Further, the change in color of the upper thread N to be used for embroidery is reduced.

Further, since a candidate of the embroidery pattern 452 in which the needle moves in the direction SD in which a change in color is small is automatically presented, the user can select the embroidery pattern 452 that can reproduce the change in color in the embroidery image 40 without being conscious of which pattern is to be selected.

Example 2

Referring to FIG. 11 and FIG. 12 , a procedure of creating embroidery data according to Example 2 is described.

FIG. 11 is a schematic diagram illustrating a procedure of creating embroidery data according to Example 2.

The embroidery image 40 is an original picture of a flower having areas in which color changes gradually or stepwise.

The embroidery image 40 includes the petal 441, the stamen 442, the peduncle 443, and the leaf 444.

The color of the petal 441 gradually or stepwise changes from white to red from the stamen 442 side toward the outward of the petal 441. A contour line of the petal 441 is drawn in black.

The image processing unit 421 automatically determines, from the embroidery image 40 of the flower, embroidery areas such as the petal 441, the stamen 442, the peduncle 443, the leaf 444, and the contour lines thereof.

The user interface unit 420 displays the determined embroidery areas on the display 406, and receives an input of the embroidery area of the petal 441 designated by the user and the embroidery pattern 452 designated by the user in the embroidery area of the petal 441.

The image processing unit 421 detects whether the embroidery area of the petal 441 designated by the user is the area 450 involving a color change.

In a case that the embroidery area of the petal 441 is the area 450 involving a color change, the image processing unit 421 detects the direction CD in which a color changes in the area 450 involving a color change.

The image processing unit 421 creates the embroidery data 41 in which the needle moves in the direction SD in which a change in color is smaller than a change in color in the direction CD in which a color changes, so that an arrangement of the upper thread N in the embroidery pattern 452 designated by the user does not change.

Flowchart of Creating Embroidery Data

Referring to FIG. 11 and FIG. 12 , a specific procedure of generating the embroidery data 41 according to the present example is described. FIG. 12 is a flowchart of an operation of creating embroidery data according to the present example. Descriptions of processes overlapping with those of Example 1 are omitted below to avoid redundancy.

The embroidery area determination unit 423 automatically determines the embroidery areas (step S100).

The embroidery area designation unit 424 receives an input of an embroidery area of the petal 441 designated by the user. The embroidery pattern designation unit 428 receives an input of the embroidery pattern 452 such as a running stitch designated by the user in the embroidery area of the petal 441 (step S200).

The area attribute detection unit 425 detects area attribute information such as color variation in the embroidery area of the petal 441 designated by the user (step S102).

When the color variation in the embroidery area of the petal 441 is equal to or greater than a threshold value (YES in step S103), the area attribute detection unit 425 determines the embroidery area of the petal 441 designated by the user as the area 450 involving a color change (color change area) (step S104).

When the color variation in the embroidery area of the petal 441 is less than the threshold value (NO in step S103), the area attribute detection unit 425 determines the embroidery area of the petal 441 designated by the user as an area not involving a color change (color constant area) (step S105).

The area attribute detection unit 425 detects the direction CD in which a color changes in the area 450 involving a color change (step S106).

The embroidery data creation unit 427 creates the embroidery data 41 in which the needle 21 moves in the direction SD in which a change in color is smaller than a change in color in the direction CD in which a color changes, so that an arrangement of the upper thread N appearing on the front side in the embroidery pattern 452 such as a running stich designated by the user does not change, and outputs the created embroidery data 41 (step S201).

Referring to FIG. 11 , in a typical running stitch, the position of the needle 21 is moved from a first position P1 to a third position P3 in order. By contrast, in the present example, the position of the needle 21 is moved from the first position, P1, a second position P2, and a fourth position P4 in order.

That is, the embroidery data creation unit 427 creates the embroidery data 41 so that embroidery is performed preferentially in the direction SD in which a change in color is small. In other words, the embroidery data creation unit 427 creates the embroidery data 41 such that embroidery is continuously performed in a portion of the same color or a similar color in the area 450 involving a color change. A range of the same color or the similar colors is a range of a color difference AE determined in advance.

According to Example 2, the embroidery data 41 according to which the needle 21 moves in the direction SD in which a change in color is small is created so that the arrangement of a thread appearing on the front side of the embroidery pattern 452 designated by the user does not change.

Thus, even when an amount of consumption of the upper thread N fluctuates while actually performing embroidery and therefore deviation of color of the upper thread N occurs, the deviation of color is less recognizable. In other words, when embroidery is performed using the upper thread N to which multiple colors are applied, a change in color in the embroidery image 40 is reproducible. Further, the change in color of the upper thread N to be used for embroidery is reduced.

Furthermore, since the change in color is reproducible by a user's designation of a desired embroidery pattern 452 without being unconscious of the change in color in the embroidery image 40, a range of design of the embroidery in the area 450 involving a change in color broadens.

Example 3

Referring to FIG. 13 and FIG. 14 , a procedure of creating embroidery data according to Example 3 is described.

FIG. 13 is a schematic diagram illustrating a procedure of creating embroidery data according to Example 3.

The embroidery image 40 includes the petal 441, the stamen 442, the peduncle 443, and the leaf 444. The petal 441, the stamen 442, the peduncle 443, and the leaf 444 are white, and contour lines thereof are drawn in black.

The image processing unit 421 automatically determines, from the embroidery image 40 of the flower, embroidery areas such as the petal 441, the stamen 442, the peduncle 443, the leaf 444, and the contour lines thereof.

The user interface unit 420 displays the determined embroidery areas on the display 406, and receives an input of the embroidery area of the petal 441 designated by a user. Further, the user interface unit 420 receives an input of the direction CD in which a color changes and a change pattern CP of color that are designated by the user in the embroidery area of the petal 441. The direction CD in which a color changes may be referred to as a “color change direction CD.” The change pattern CP of color may be referred to as a “color change pattern.”

The color change direction CD is, for example, a linear direction. Alternatively, the color change direction CD may be, for example, a radial direction from the center of a circle or a circumferential direction around the center of the circle. The color change pattern CP is, for example, a linear gradation. Alternatively, the color change pattern CP may be, for example, a circular gradation or a stripe gradation.

The image processing unit 421 reads the embroidery pattern 452 corresponding to the color change direction CD and the color change pattern CP from the embroidery pattern storage unit 430, to automatically determine the embroidery pattern 452.

The embroidery pattern 452 corresponding to the color change direction CD and the color change pattern CP is an embroidery pattern in which a thread appearing on the front side of the embroidery pattern 452 runs in the direction SD in which a change in color small and the color of the thread of the embroidery pattern 452 changes in accordance with the color change pattern CP.

According to the determined embroidery pattern 452, the image processing unit 421 creates the embroidery data 41 so that the needle moves in the direction SD in which a change in color is smaller than a change in color in the direction CD in which a color changes.

Flowchart of Creating Embroidery Data

Referring to FIG. 13 and FIG. 14 , a specific procedure of generating the embroidery data 41 according to the present example is described. FIG. 14 is a flowchart of an operation of creating embroidery data according to the present example. Descriptions of processes overlapping with those of Example 1 and Example 2 are omitted below to avoid redundancy.

The embroidery area determination unit 423 automatically determines the embroidery areas (step S100).

The embroidery area designation unit 424 receives an input of an embroidery area of the petal 441 designated by the user. The area attribute designation unit 429 receives an input of the color change direction CD and the color change pattern CP that are designated by the user in the embroidery area of the petal 441 (step S300).

The embroidery pattern determination unit 426 reads out from the embroidery pattern storage unit 430 the embroidery pattern 452 corresponding to the color change direction CD and the color change pattern CP designated by the user, to automatically determine the embroidery pattern 452 (S301).

The embroidery pattern 452 corresponding to the color change direction CD and the color change pattern CP is an embroidery pattern in which a thread appearing on the front side of the embroidery pattern 452 runs in the direction SD in which a change in color small and the color of the thread of the embroidery pattern 452 changes in accordance with the color change pattern CP.

According to the determined embroidery pattern 452, the embroidery data creation unit 427 creates the embroidery data 41 according to which the needle 21 moves in the direction SD in which a change in color is smaller than a change in color in the direction CD in which a color changes and outputs the created embroidery data 41 (step S302).

That is, the embroidery data creation unit 427 creates the embroidery data 41 so that embroidery is performed preferentially in the direction SD in which a change in color is small. In other words, the embroidery data creation unit 427 creates the embroidery data 41 such that embroidery is continuously performed in a portion of the same color or a similar color in the area 450 involving a color change. A range of the same color or the similar colors is a range of a color difference AE determined in advance.

According to Example 3, the embroidery data 41 is created according to the embroidery pattern 452 corresponding to the color change direction CD and the color change pattern CP that are designated by the user.

Thus, even when an amount of consumption of the upper thread N fluctuates while actually performing embroidery and therefore deviation of color of the upper thread N occurs, the deviation of color is less recognizable. In other words, when embroidery is performed using the upper thread N to which multiple colors are applied, a change in color in the embroidery image 40 is reproducible. Further, the change in color of the upper thread N to be used for embroidery is reduced.

Further, since the user can designate the color change direction CD and the color change pattern CP for a desired area in the embroidery image 40, a range of color design in the desired embroidery area broadens.

Comparative Example 1

Referring to FIG. 15 , an overview of a procedure of creating embroidery data according to Comparative Example 1 is described.

FIG. 15 is a schematic diagram illustrating a procedure of creating embroidery data according to Comparative Example 1. An embroidery data creation apparatus of Comparative Example 1 creates the embroidery data 41 without consideration of the color change direction CD in the area 450 involving a color change.

The embroidery image 40 is an original picture of a flower having areas in which color changes gradually or stepwise.

The embroidery image 40 includes the petal 441, the stamen 442, the peduncle 443, and the leaf 444.

The color of the petal 441 gradually or stepwise changes from white to red from the stamen 442 side toward the outward of the petal 441. A contour line of the petal 441 is drawn in black.

The embroidery data creation apparatus of Comparative Example 1 automatically determines, from the embroidery image 40 of the flower, embroidery areas such as the petal 441, the stamen 442, the peduncle 443, the leaf 444, and the contour lines thereof.

The embroidery data creation apparatus of Comparative Example 1 displays the determined embroidery areas on the display 406, and receives an input of the embroidery area of the petal 441 designated by the user and the embroidery pattern 452 designated by the user in the embroidery area of the petal 441.

The embroidery data creation apparatus of Comparative Example 1 creates the embroidery data 41 according to which the movement position of the needle 21 moves from a start position SP1 to an end position EP1 and moves from a start position SP2 to an end position EP2 according to the embroidery pattern 452 designated by the user.

However, according to the embroidery data 41 of Comparative Example 1, a large number of color changes occurs in a color of the upper thread N to be used. Further, in a case that thread cutting is performed between the EP1 and the SP2, an extreme change in color occurs in a portion of the upper thread N at the boundary between the EP1 and the SP2.

Furthermore, in a case that a complicated change in color occurs in the upper thread N to be prepared, when a consumption amount of the upper thread N is changed while actually performing embroidery, a deviation of the color of the upper thread N occurs.

FIG. 16 is a diagram illustrating a deviation of color of a thread based on the embroidery data 41 according to Comparative Example 1. Since the embroidery data 41 of Comparative Example 1 is created without consideration of the color change direction CD in the area 450 involving a color change, a deviation of color of the upper thread N occurs when the embroidery is performed using a thread to which multiple colors are applied.

Comparative Example 2

Referring to FIG. 17 , an overview of a procedure of creating embroidery data according to Comparative Example 2 is described.

FIG. 17 is a schematic diagram illustrating a procedure of creating embroidery data according to Comparative Example 2. An embroidery data creation apparatus of Comparative Example 2 creates the embroidery data 41 for performing embroidery using a single-color thread.

The embroidery image 40 is an original picture of a flower having areas in which color changes gradually or stepwise.

The embroidery image 40 includes the petal 441, the stamen 442, the peduncle 443, and the leaf 444.

The color of the petal 441 gradually or stepwise changes from white to red from the stamen 442 side toward the outward of the petal 441. A contour line of the petal 441 is drawn in black.

The embroidery data creation apparatus of Comparative Example 2 automatically determines, from the embroidery image 40 of the flower, embroidery areas such as the petal 441, the stamen 442, the peduncle 443, the leaf 444, and the contour lines thereof.

The embroidery data creation apparatus of Comparative Example 2 displays the determined embroidery areas on the display 406, and receives an input of the embroidery area of the petal 441 designated by the user and the embroidery pattern 452 designated by the user in the embroidery area of the petal 441.

According to the embroidery pattern 452 designated by the user, the embroidery data creation apparatus of Comparative Example 2 creates the embroidery data 41 that is optimized in consideration of a direction of a thread seam that is less likely to be distorted and a small number of thread cuttings.

However, the embroidery data 41 of Comparative Example 2 is embroidery data according to which embroidery is performed using a single-color thread. For this reason, even when in the embroidery pattern 452, the needle moves in the direction SD in which a change in color is small, thread cutting is performed very often according to such the embroidery data 41.

According to the embroidery data 41 of Comparative Example 2, the needle 21 is advanced from the start position SP1 to the end position EP1, and then the upper thread N of white is cut. Next, the upper thread N of white is replaced with the upper thread N of pink, the needle 21 is advanced from the start position SP2 to the end position EP2, then the upper thread N of pink is cut.

Next, the upper thread N of pink is replaced with the upper thread N of dark pink, the needle 21 is advanced from a start position SP3 to an end position EP3, and then the upper thread N of dark pink is cut. Next, the upper thread N of dark pink is replaced with the upper thread N of light red, the needle 21 is advanced from a start position SP4 to an end position EP4, and the upper thread N of light red is cut. Finally, the upper thread N of light red is replaced with the upper thread N of red, the needle 21 is advanced from a start position SP5 to an end position EP5, the upper thread N of red is cut.

Thus, according to the embroidery data 41 of Comparative Example 2, a thread cutting processes and a replacement processes of the upper thread N have to be performed very often.

A description is now given of modifications of Example 1 to Example 3.

Modification 1

In FIG. 8 , in a case that the degree of linearity in the area 450 involving a change in color is greater than a threshold value, the embroidery pattern determination unit 426 may determine a stitch suitable for a linear area as a stitch to be applied to the area 450 involving a change in color. Examples of the stitch suitable for the linear area include a running stitch and a back stitch.

In a case that the degree of circularity in the area 450 involving a change in color is greater than a threshold value, the embroidery pattern determination unit 426 may determine a stitch suitable for a circular area as a stitch to be applied to the area 450 involving a change in color. Examples of the stitch suitable for a circular area include a satin stitch and a fill stitch.

The degree of linearity is πL²/4×S. The circularity is 4πS/L². “L” represents is a peripheral length. “S” represents a size (number of pixels).

When the size or the degree of circularity of the area 450 involving a change in color is smaller than the threshold value, the embroidery pattern determination unit 426 may reduce a thread density of the embroidery area. When the size or the degree of circularity of the area 450 involving a change in color is larger than the threshold value, the embroidery pattern determination unit 426 may increase a thread density of the embroidery pattern 452.

According to Modification 1, the embroidery pattern determination unit 426 determines the embroidery pattern 452 to be applied to the area 450 involving a change in according to not only the area attribute information relating to color but also the area attribute information relating to a shape such as a size, linearity, and circularity. With this configuration, the embroidery pattern 452 that is suitable for the area 450 involving a change in color is provided to a user.

Modification 2

In FIG. 9 , the area attribute detection unit 425 detects, for each pixel, the color change vector CV and the color constant vector SV indicating a direction in which a color change is smaller than a color change of the color change vector CV in the area 450 involving a color change. The embroidery pattern determination unit 426 may determine a length of stitches of the thread in the embroidery pattern 452 in accordance with the magnitude of the color constant vector SV.

According to Modification 2, the larger the magnitude of the color constant vector SV, the longer the thread stitch. The smaller the magnitude of the color constant vector SV, the shorter the thread stitch. With this configuration, a sharp change in color or a gradual change in color in the area 450 involving a change in color can be reproduced.

Modification 3

In FIG. 6 , the embroidery data creation unit 427 may create dyeing data to be used in the dyeing apparatus 1 according to the embroidery image 40 and the embroidery data 41 (initial embroidery data).

The embroidery data creation unit 427 may create the embroidery data 41 obtained by adding the underlay stitching data to the initial embroidery data according to the dyeing data.

The third communication control unit 432 transmits the dyeing data to the dyeing apparatus 1 and transmits the embroidery data 41 to which the underlay stitching data is added to the embroidery apparatus 2.

The first communication control unit 120 receives the dyeing data through a wired network or a wireless network. The dyeing data processing unit 121 sends a dyeing command obtained by processing the dyeing data to the head driver 39.

The second communication control unit 240 receives the embroidery data 41 to which the underlay stitching data is added through a wired network or a wireless network. The embroidery data processing unit 241 sends an operation command obtained by processing the embroidery data 41 to the motor driver 26.

According to Modification 3, the data processing functions performed by the dyeing apparatus 1 and the embroidery apparatus 2 can be integrated into the embroidery data creation apparatus 4. This simplifies management of a program relating to forming embroidery.

Modification 4

In FIG. 6 , the embroidery data creation unit 427 may create the embroidery data 41 obtained by adding the underlay stitching data to the initial embroidery data according to dyeing data received from the dyeing apparatus 1.

The third communication control unit 432 transmits the embroidery data 41 to which the underlay stitching data is added to the embroidery apparatus 2.

According to Modification 4, the data processing functions performed by the embroidery apparatus 2 can be integrated into the embroidery data creation apparatus 4. This simplifies management of a program relating to forming embroidery.

The functionality of the elements disclosed herein may be implemented using circuitry or processing circuitry which includes general purpose processors, special purpose processors, integrated circuits, application specific integrated circuits (ASICs), digital signal processors (DSPs), field programmable gate arrays (FPGAs), conventional circuitry and/or combinations thereof which are configured or programmed to perform the disclosed functionality. Processors are considered processing circuitry or circuitry as they include transistors and other circuitry therein. In the disclosure, the circuitry, units, or means are hardware that carry out or are programmed to perform the recited functionality. The hardware may be any hardware disclosed herein or otherwise known which is programmed or configured to carry out the recited functionality. When the hardware is a processor which may be considered a type of circuitry, the circuitry, means, or units are a combination of hardware and software, the software being used to configure the hardware and/or processor.

An embroidery data creation apparatus according to the related art creates embroidery data on the assumption that embroidery is performed using a single-color thread. When embroidery is performed according to embroidery data using a thread to which multiple colors are applied, in some cases, a change in color in an embroidery image is not reproduced.

According to one embodiment of the present disclosure, a technology is provided that is excellent in reproducibility of a change in color in an embroidery image when embroidery is performed using a threads to which multiple colors are applied.

Aspects of the present disclosure are as follows, for example.

Aspect 1

According to Aspect 1, an embroidery data creation apparatus outputs embroidery data created according to an embroidery image as a source of embroidery.

The embroidery data creation apparatus includes an embroidery data creation unit that creates the embroidery data according to which embroidery is performed using a thread to which multiple colors are applied so as to advance the embroidery in a direction in which a change in a color is smaller than a change in the color in a direction in which the color changes in an area involving the change in the color in the embroidery image.

Aspect 2

According to Aspect 2, the embroidery data creation apparatus of Aspect 1 further includes an area attribute detection unit that detects the direction in which the color changes according to color information of respective pixels in the area involving the change in the color in the embroidery image.

Aspect 3

According to Aspect 3, the embroidery data creation apparatus of Aspect 1 further includes an embroidery image acquisition unit that acquires the embroidery image as print data. The embroidery data creation apparatus further includes an area attribute detection unit that detects the direction in which the color changes according to a blending amount of the color included in the print data.

Aspect 4

According to Aspect 4, the embroidery data creation apparatus of any one of Aspect 1 to Aspect 3 further includes an embroidery pattern determination unit that determines one or more candidates of an embroidery pattern that advances in the direction in which the change in the color is smaller.

The embroidery data creation apparatus further includes an embroidery pattern designation unit that receives an input of a particular embroidery pattern designated by a user from among the one or more candidates of the embroidery pattern.

Aspect 5

According to Aspect 5, the embroidery data creation apparatus of any one of Aspect 1 to Aspect 3 further includes an embroidery pattern designation unit that receives an input of an embroidery pattern designated by a user.

The embroidery data creation unit creates the embroidery data according to which the embroidery pattern is advanced in the direction in which the change in the color is smaller so that an arrangement of the thread appearing on a front side of the embroidery pattern does not change.

Aspect 6

According to Aspect 6, the embroidery data creation apparatus of any one of Aspect 1 to Aspect 3 further includes an embroidery pattern determination unit that determines an embroidery pattern corresponding to a color change direction and a color change pattern that are designated by a user.

Aspect 7

According to Aspect 7, in the embroidery data creation apparatus of any one of Aspect 1 to Aspect 6, the embroidery data creation unit creates the embroidery data so that the embroidery is advanced preferentially in the direction in which the change in the color is smaller.

Aspect 8

According to Aspect 8, in the embroidery data creation apparatus of any one of Aspect 1 to Aspect 7, the embroidery data creation unit creates the embroidery data so as to continuously perform the embroidery in a portion of a same color or a similar color in the area involving the change in the color.

Aspect 9

According to Aspect 9, an embroidery data creation method is performed by an embroidery data creation apparatus that outputs embroidery data created according to an embroidery image as a source of embroidery.

The method includes creating the embroidery data according to which embroidery is performed using a thread to which multiple colors are applied so as to advance the embroidery in a direction in which a change in a color is smaller than a change in the color in a direction in which the color changes in an area involving the change in the color in the embroidery image.

Aspect 10

According to Aspect 10, an embroidery apparatus includes an embroidery data creation unit that creates embroidery data according to which embroidery is performed using a thread to which multiple colors are applied so as to advance the embroidery in a direction in which a change in a color is smaller than a change in the color in a direction in which the color changes in an area involving the change in the color in an embroidery image as a source of the embroidery.

The embroidery apparatus further includes an embroidery forming section that performs the embroidery according to the embroidery data.

Aspect 11

According to Aspect 11, a liquid discharge apparatus includes an embroidery data creation unit that creates embroidery data according to which embroidery is performed using a thread to which multiple colors are applied so as to advance the embroidery in a direction in which a change in a color is smaller than a change in the color in a direction in which the color changes in an area involving the change in the color in an embroidery image as a source of the embroidery.

The liquid discharge apparatus further includes a liquid discharge section that discharges a liquid as a source of the color to the thread according to the embroidery image and the embroidery data.

Aspect 12

According to Aspect 11, a program causes a computer to perform a step of creating embroidery data according to which embroidery is performed using a thread to which multiple colors are applied so as to advance the embroidery in a direction in which a change in a color is smaller than a change in the color in a direction in which the color changes in an area involving the change in the color in an embroidery image as a source of the embroidery, and outputting the created embroidery data.

The above-described embodiments are illustrative and do not limit the present invention. Thus, numerous additional modifications and variations are possible in light of the above teachings. For example, elements and/or features of different illustrative embodiments may be combined with each other and/or substituted for each other within the scope of the present invention. Any one of the above-described operations may be performed in various other ways, for example, in an order different from the one described above. 

1. An embroidery data creation apparatus comprising: circuitry configured to: create embroidery data based on an embroidery image, the embroidery image being a source of embroidery to be performed according to the embroidery data using a thread to which multiple colors are applied, the embroidery data being created such that, in an area involving change in a color in the embroidery image, the embroidery is advanced in a first direction being a direction in which a change in the color is smaller than a change in the color in a second direction in which the color changes; and output the created embroidery data.
 2. The embroidery data creation apparatus of claim 1, wherein the circuitry is further configured to detect the second direction in which the color changes according to respective color information of pixels in the area involving the change in the color in the embroidery image.
 3. The embroidery data creation apparatus of claim 1, wherein the circuitry is further configured to: acquire the embroidery image as print data; and detect the second direction in which the color changes, according to a blending amount of the color included in the print data.
 4. The embroidery data creation apparatus of claim 1, wherein the circuitry is further configured to: determine one or more candidates of an embroidery pattern that advances in the first direction in which the change in the color is smaller; and receive an input of a particular embroidery pattern designated by a user from among the one or more candidates of the embroidery pattern.
 5. The embroidery data creation apparatus of claim 1, wherein the circuitry is further configured to: receive an input of an embroidery pattern designated by a user; and create the embroidery data for advancing the embroidery pattern in the first direction in which the change in the color is smaller, so that an arrangement of the thread appearing on a front side of the embroidery pattern remains unchanged.
 6. The embroidery data creation apparatus of claim 1, wherein the circuitry is further configured to determine an embroidery pattern corresponding to a change direction of the color and a change pattern of the color that are designated by a user.
 7. The embroidery data creation apparatus of claim 1, wherein the circuitry is further configured to create the embroidery data so that the embroidery is advanced preferentially in the first direction in which the change in the color is smaller.
 8. The embroidery data creation apparatus of claim 1, wherein the circuitry is further configured to create the embroidery data so that the embroidery is continuously performed in a portion of a same color or similar colors in the area involving the change in the color.
 9. An embroidery data creation method performed by an embroidery data creation apparatus, the method comprising: creating embroidery data based on an embroidery image, the embroidery image being a source of embroidery to be performed according to the embroidery data using a thread to which multiple colors are applied, the embroidery data being created such that, in an area involving a change in a color in the embroidery image, the embroidery is advanced in a first direction being a direction in which a change in the color is smaller than a change in the color in a second direction in which the color changes; and outputting the created embroidery data.
 10. An embroidery apparatus comprising: the embroidery data creation apparatus of claim 1; and an embroidery forming section configured to perform the embroidery according to the embroidery data.
 11. A liquid discharge apparatus comprising: the embroidery data creation apparatus of claim 1; and a liquid discharge section configured to discharge a liquid as a source of the color to the thread according to the embroidery image and the embroidery data.
 12. A non-transitory computer-executable medium storing a program storing instructions which, when executed by a processor of a computer, causes the processor to perform a method comprising: creating embroidery data based on an embroidery image, the embroidery image being a source of embroidery to be performed according to the embroidery data using a thread to which multiple colors are applied, the embroidery data being created such that, in an area involving a change in a color in the embroidery image, the embroidery is advanced in a first direction being a direction in which a change in the color is smaller than a change in the color in a second direction in which the color changes; and outputting the created embroidery data. 